Molded article transfer device

ABSTRACT

A molded article transfer device ( 150, 250 ) is described herein that is associated, in use, with an injection mold ( 100, 200 ). The molded article transfer device ( 150, 250 ) includes a transfer structure ( 151, 251 ) that defines, amongst other things, a first aperture ( 154 A) that is structured to receive a first molded article ( 102 A) from a first mold stack ( 106 A,  206 A) of the injection mold ( 100 ). The transfer structure ( 151, 251 ) also defines a first branch channel ( 156 A) and a first trunk channel ( 158 A) through which the first molded article ( 102 A) is passable. The first branch channel ( 156 A) connects the first aperture ( 154 A) with the first trunk channel ( 158 A) for passing, in use, the first molded article ( 102 A) thereto, whereafter it passes through the first trunk channel ( 158 A) towards an exit ( 164 A) thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.13/202,787 filed Aug. 23, 2011, which is the U.S. National Stage ofPCT/CA2010/001714, filed Nov. 3, 2010, which claims priority from U.S.Provisional patent application 61/285,305 filed Dec. 10, 2009, thedisclosures of which are incorporated herein by reference.

TECHNICAL FIELD

The non-limiting embodiments disclosed herein generally relate to amolding apparatus, and more particularly to a molded article transferdevice and a controller to execute a molding process.

BACKGROUND

U.S. Pat. No. 7,351,050 to Vanderploeg et al, published on Apr. 1, 2008teaches a servo side shuttle apparatus and method for a molding machineincludes structure and/or steps whereby a shuttle plate is disposedadjacent at least one of a first mold half and a second mold half of themolding machine. A guidance assembly is coupled to the mold half andguides the shuttle plate linearly across a molding face of the moldhalf. A drive mechanism is provided to drive the shuttle plate in alinear direction. An operation structure is coupled to the shuttle plateand is configured to perform an operation on a molded article disposedeither in the mold cavity or on the mold core. The operation may includeremoving the molded article from a mold core, applying a label to a moldcavity, and/or closing the lid of a molded article while it is residenton the mold core.

U.S. Pat. No. 5,037,597 to McGinley et al, published on Aug. 6, 1991teaches an injection molding apparatus and process for forming aplurality of first parts and a plurality of complementary second partsduring a single molding cycle has a system for removing parts moldedduring each cycle and for assembling the parts into finished articles.The system includes a plurality of rotatable suction cups for removingthe parts and for aligning them with and inserting them into a series ofloading ports in a central mold member so as to mate respective ones ofthe first parts with respective ones of the second parts. The centralmold member further has internal chute assemblies for conveyingassembled articles away from the mold. A novel system for driving therotatable suction cups uses a rotatable member mounted to various moldhalves and a camming arrangement whereby relative movement of the moldhalves during the mold closing and opening motions causes rotation ofthe suction cups.

U.S. Pat. No. 4,715,806 to Ehrler et al, published on Dec. 29, 1987teaches a sprue part that is cut and removed from the injection moldpart during the manufacture of information storage disks by an injectionmolding process. The highly sensitive molding of an information storagedisk is protected from damage by the sprue and the deposition of dustparticles during stripping by this process. The sprue is punched into apart serving as the die of the injection molding tool and subsequentlyremoved, in particular by suction, through an orifice leading frominside the part, together with the dust particles generated in thepunching process. Preferably, the sprue is punched out and removed withthe injection molding tool closed. The injection molding tool must beopened only after the sprue and the dust have already been removed, thusensuring that the molded product has an especially good quality.

U.S. Pat. Nos. 4,981,634 and 5,141,430 to Maus et al, published on Jan.1, 1991, and Aug. 25, 1992, respectively, teach an injection moldingprocess creates a micro clean room environment inside a mold cavitywhich can stay closed to airborne contaminants while ejecting andtransferring the molded part out. The molded part is formed andsolidified at a parting line plane within the mold cavity, then iscarried rearward on the movable mold insert to a second plane where itis stripped off and transferred out through a discharge aperture whichis open when the mold cavity is in the second plane but closed off whenin the first plane. The aperture faces substantially downward to prevententry by upwelling thermal air currents. External supplied filtered gascan provide positive pressure through vents within the moldset'sinternal space. This maximizes mold and part cleanliness while speedingup “mold-open” cycle; may eliminate HEPA filters/enclosures and robots.Optical disks, lenses, food packaging and medical parts are suggesteduses.

U.S. Pat. No. 4,589,840 to Schad, published on May 20, 1986 teaches anapparatus for continuously receiving and collecting molded articles froma continuously cycling injection molding machine where the articles arecollected sequentially and continuously in a uniform physical positionor orientation.

U.S. Pat. No. 6,939,504 to Homann et al, published on Sep. 6, 2005teaches a method and system for producing hollow rib structures for trimcomponents and panels using gas assisted injection molding. Movableinsert members are provided in the mold cavity, particularly at the endsof the structural rib members. After the plastic material is injectedinto the mold cavity, the plastic is packed in the mold, and the insertmembers are locked in position. Selectively activatable lockingmechanisms are used to lock up the insert members. Thereafter, gas oranother fluid is introduced into the rib members in order to providehollow channels therein. Movement of the insert members provides arecess or groove for placement of the displaced resin from the ribmembers. The displaced resin material completes the formation of themolded plastic article.

U.S. Pat. No. 5,244,606 to Maus et al, published on Sep. 14, 1993teaches a molded disk is transferred out of the mold with short-strokelow-mass motions of a pair of mechanical guides which can grip, thenrelease, the O.D. edge of the molded disk, when acting in coordinationwith movable mold members having undercuts for molded-on retention ofthe inner portion of the molded disk and/or sprue. Acting together, thedisk is stripped off the molding surfaces and can be oriented in asecond vertical plane to freely drop out an aperture in the mold, toexit through a discharge chute. Two ways of separating the sprue fromthe disk are shown, with a molded-in centerhole being preferred. Thismethod and apparatus for transferring the molded disk out faster bygravity discharge wherein an optical disk mold can be enclosed againstairborne dirt throughout molding cycles.

U.S. Pat. No. 4,438,065 to Brown et al, published on Mar. 20, 1984teaches an improvement in an injection molding apparatus for acontainer, where the apparatus includes a core defining the interior ofthe container and first means within the core for initiating ejection ofa molded container from the core. The improvement consists of secondmeans adjacent the rim of the molded container for blowing a gaseousmaterial toward the container rim, thereby completing ejection by urgingthe container away from the core.

SUMMARY

According to an aspect described herein, there is provided a moldedarticle transfer device that is associated, in use, with an injectionmold. The molded article transfer device includes a transfer structurethat defines, amongst other things, a first aperture that is structuredto receive a first to molded article. The transfer structure alsodefines a first branch channel and a first trunk channel through whichthe first molded article is passable. The first branch channel connectsthe first aperture with the first trunk channel for passing, in use, thefirst molded article thereto, whereafter it passes through the firsttrunk channel towards an exit thereof.

According to another aspect described herein, there is provided acontroller including instructions being embodied in a controller-usablememory of the controller, the instructions for directing the controllerto execute a molding process. The molding process includes: closing afirst mold stack of an injection mold; molding a first molded articlewithin the first mold stack; opening the first mold stack; arranging thefirst mold stack to eject the first molded article into the firstaperture; and dispensing fluid through a first nozzle that is defined bythe transfer structure to urge the first molded article that is receivedin the first aperture to pass through a first branch channel towards afirst trunk channel that are defined by the transfer structure.

These and other aspects and features will now become apparent to thoseskilled in the art upon review of the following description of specificnon-limiting embodiments in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE DRAWINGS

The detailed description of illustrative (non-limiting) embodiments willbe more fully appreciated when taken in conjunction with theaccompanying drawings, in which:

FIG. 1 depicts a schematic representation of an injection molding systemhaving a non-limiting embodiment of an injection mold arranged therein;

FIG. 2A depicts a section view through a portion of the injection molddepicted in FIG. 1 arranged in a mold closed configuration, and of amolded article transfer device that is associated therewith;

FIG. 2B depicts a section view through the portion of the injection molddepicted in FIG. 2A arranged in a mold open configuration;

FIG. 3 depicts a perspective view of the portion of the injection moldof FIG. 2A that reveals a first nozzle that is associated with themolded article transfer device;

FIG. 4 depicts a front view of another portion of a first mold half ofthe injection mold of FIG. 1 including the molded article transferdevice;

FIG. 5 depicts a front view of another portion of the first mold halfincluding an alternate non-limiting embodiment of the molded articletransfer device;

FIGS. 6A-6G depict a sequence of section views of the portion theinjection mold of FIG. 2A further including an in-mold shutter thatillustrate the configuration thereof during various steps of anon-limiting injection molding process;

FIG. 7 depicts a section view through a portion of an alternatenon-limiting embodiment the injection mold arranged in a mold closedconfiguration;

FIG. 8 depicts a flow chart of a first aspect of the injection moldingprocess.

The drawings are not necessarily to scale and may be illustrated byphantom lines, diagrammatic representations and fragmentary views. Incertain instances, details that are not necessary for an understandingof the embodiments or that render other details difficult to perceivemay have been omitted.

DETAILED DESCRIPTION OF THE NON-LIMITING EMBODIMENT(S)

FIG. 1 depicts a schematic representation of an injection molding system900 with a non-limiting embodiment of an injection mold 100 arrangedtherein. The injection mold 100 is operable to mold a first moldedarticle 102A (FIG. 2B or 4) such as, for example, a container closure.

In the description of the injection molding system 900 and the injectionmold 100 that follows many of the components thereof are known topersons skilled in the art, and as such these known components will notbe described in detail herein. A detailed description of these knowncomponents may be referenced, at least in part, in the followingreference books (for example): (i) “Injection Molding Handbook” authoredby OSSWALD/TURNG/GRAMANN (ISBN: 3-446-21669-2), (ii) “Injection MoldingHandbook” authored by ROSATO AND ROSATO (ISBN: 0-412-10581-3), (iii)“Injection Molding Systems” 3rd Edition authored by JOHANNABER (ISBN3-446-17733-7) and/or (iv) “Runner and Gating Design Handbook” authoredby BEAUMONT (ISBN 1-446-22672-9).

The injection molding system 900 shown in FIG. 1 is shown to include,but is not limited to, a clamping assembly 996 and an injection assembly997.

By way of example, the clamping assembly 996 described hereafter isrepresentative of a typical three-platen variety although no suchspecific limitation on the generality of the construction and/oroperation thereof is intended. As such the clamping assembly 996 mayhave a different construction, such as, for example, one having onlytwo-platens. That being said, the non-limiting embodiment of theclamping assembly 996 includes, amongst other things, a moving platen912, a stationary platen 914, a clamp block 913, and a tie bar 916. Thetie bar 916 links the stationary platen 914 with the clamp block 913,and moreover slidably supports the moving platen 912 thereon. While forthe sake of simplicity of depiction only one tie bar 916 is shown, it istypical to provide four such tie bars 916, one extending between each ofthe four corners of the moving platen 912, the stationary platen 914,and the clamp block 913. The clamping assembly 996 also includes aplaten-moving actuator 915 (such as, for example, a hydraulic actuator,a pneumatic actuator, an electro-mechanical actuator, or the like) thatis connected between the moving platen 912 and the clamp block 913. Theplaten-moving actuator 915 is operable, in use, to move the movingplaten 912 with respect to the stationary platen 914 and thus move afirst mold half 96 with respect to a second mold half 98 that aremounted thereto, respectively. The clamping assembly 996 furtherincludes a clamp actuator 918 and a clamp shutter 920 in associationwith the clamp block 913. The clamp shutter 920 is operable, in use, toselectively connect the clamp actuator 918 with the moving platen 912for sake of a clamping together of the first mold half 96 and the secondmold half 98. Lastly, the clamping assembly 996 may also include anejector actuator 922 (such as, for example, a hydraulic actuator, apneumatic actuator, an electro-mechanical actuator, or the like) that isassociated with the moving platen 912. The ejector actuator 922 isconnectable to a structure that is associated with the first mold half96. The structure of the first mold half 96 is driven, in use, withactuation of the ejector actuator 922, whereby an operation isperformed, such as, for example, ejecting the first molded article 102A(FIG. 4) from the first mold half 96.

By way of example, the injection assembly 997 described hereafter isrepresentative of a typical reciprocating screw variety although nospecific limitation on the generality of a construction and/or operationthereof is intended. As such the injection assembly 997 may have adifferent construction, such as, for example, one having separateplasticizing and injection means (i.e. so-called two stage variety). Theinjection assembly 997 is operable to melt and inject a moldingmaterial, such as, for example, Polyethylene orPolyethylene-terephthalate (PET) through a machine nozzle (not shown)and into a melt distribution apparatus 190 (e.g. hot runner, coldrunner, insulated runner, or the like) that is associated with thesecond mold half 98. The melt distribution apparatus 190 in turn directsthe molding material into one or more molding cavity 101 (FIG. 2A) thatare defined within the injection mold 100 with the first mold half 96and the second mold half 98 being closed and clamped together.

The focus of the description shall now shift to the construction andoperation of the non-limiting embodiment of the injection mold 100 shownin FIG. 2A including a non-limiting embodiment of a molded articletransfer device 150 that is associated therewith. The molded articletransfer device 150 is operable to transfer the first molded article102A that is received from a first mold stack 106A of the injection mold100.

As shown in FIG. 2A, the first mold half 96 includes a first mold shoe130 to which a first stack portion 110 of the first mold stack 106A andthe molded article transfer device 150 are connected. The second moldhalf 98 includes a second mold shoe 131 to which a second stack portion120 of the first mold stack 106A is connected. The first stack portion110 and the second stack portion 120 are positioned, in use, relative toeach other, along a mold-stroke axis X of the injection mold 100, toclose and open a molding cavity 101 that is defined therebetween formolding and ejecting the first molded article 102A (FIG. 2A).

The first stack portion 110 of the first mold stack 106A includes aninner core 112, an outer core 114, and a stripper sleeve 116 thatcooperate, in use, with a cavity insert 122 of the second stack portion120 to define the molding cavity 101.

The outer core 114 is slidably arranged around the inner core 112 toaccommodate, in use, relative movement thereof along the mold-strokeaxis X, a technical effect of which may include, for example, therelease of a seal portion 103 (FIG. 6D) of the first molded article102A. Likewise, the stripper sleeve 116 is slidably arranged around theouter core 114 to accommodate, in use, the relative movement thereofalong the mold-stroke axis X, a technical effect of which may include,for example, the stripping of the first molded article 102A from theouter core 114.

As previously alluded to, the outer core 114 and the inner core 112 areslidably retained together to limit, in use, the relative movementthereof, in use, along the mold-stroke axis X. For example, the innercore 112 may be structured to define a bayonet 113 and the outer core114 structured to define a bayonet pocket 117, wherein the bayonet 113and the bayonet pocket 117 are configured to cooperate, when rotatablyengaged, to slidably retain the outer core 114 about the inner core 112.In operation the inner core 112 and the outer core 114 are keptrotatably engaged by a key 119. The key 119 is fixed to the second coreretainer 133 such that a portion thereof extends into the passageway 139with which to cooperate with the outer core 114 to maintain an angularorientation thereof with respect to the inner core 112.

The first stack portion 110 further includes a resilient member 115 thatis arranged between the inner core 112 and the outer core 114, andwherein the resilient member 115 is arranged to bias the outer core 114towards a forward limit of travel with respect to the stripper sleeve116 that corresponds with their relative arrangement during the moldingof the first molded article 102A—as shown in FIG. 2A.

As previously mentioned, the foregoing members of the first stackportion 110 are connected to the first mold shoe 130. Now, in moredetail, the first mold shoe 130 includes a first core retainer 132, asecond core retainer 133, and a stripper retainer 136 that are slidablyconnected together to accommodate the relative movement thereof, in use,along the mold-stroke axis X. As such, the inner core 112 is fixed tothe first core retainer 132. The outer core 114 is slidably arrangedwithin a passageway 139 that is defined in the second core retainer 133and as such is movable relative thereto to accommodate, in use, movementthereof, along the mold-stroke axis X, from a outer core moldingposition (FIG. 2A) to a stripping position (FIG. 2B). Lastly, thestripper sleeve 116 is slidably retained within a pocket 138 that isdefined in the stripper retainer 136 and as such is movable relativethereto to accommodate, in use, movement thereof, along the mold-strokeaxis X, from a stripper sleeve molding position (FIG. 2A) to an ejectionposition (FIG. 2B). Of note, the stripper retainer 136 includes a baseplate 134 and a top plate 135 that are fastened together, in use, todefine the pocket 138 with a flange 123 of the stripper sleeve slidablyretained therein.

Of further note, the inner core 112 is shown to be connected to thefirst core retainer 132 in a fluid tight manner to isolate a coolantcircuit that is defined therein. The coolant circuit is defined betweena coolant dispenser 193 and a space that is defined within the innercore 112 within which the coolant dispenser 193 is arranged. An endportion of the coolant dispenser 193 is connected to the first coreretainer 132 and is otherwise arranged to direct coolant, in use,between a coolant inlet conduit 191 and a coolant outlet conduit 194that are defined in the first core retainer 132. In operation, acoolant, such as water, is circulated through the coolant channel toremove heat from the inner core 112, and any of the other members of thefirst mold stack 106A that are thermally connected therewith, wherebythe first molded article 102A may be rapidly cooled to ensure a fastermolding cycle.

The relative movement between the first core retainer 132 and thestripper retainer 136 of the first mold shoe 130, along the mold-strokeaxis X, may be driven, in use, by a stripper actuator 153 that isconnected thereto. More particularly, with positioning of the injectionmold 100 between a mold closed configuration C, as shown in FIG. 2A, anda mold open configuration O, as shown in FIG. 2B, with relative movementbetween the moving platen 912 and the stationary platen 914, thestripper actuator 153 is operable to extend and retract, as required,the stripper retainer 136 relative to the first core retainer 132 alongthe mold-stroke axis X. That being said, the stripper actuator 153 maybe a spring-type actuator (e.g. coil, or air-spring) to bias thestripper retainer 136 to extend relative to the first core retainer 132,along the mold-stroke axis X, with opening of the injection mold 100,and that the retraction of the stripper retainer 136 relative to thefirst core retainer 132 may be provided with closing of the injectionmold 100. Furthermore, the ejector actuator 922 of the clamping assembly996 may be connected to the second core retainer 133 for a repositioningthereof, along the mold-stroke axis X.

As previously mentioned, and as shown with reference to FIGS. 2A and 2B,the molded article transfer device 150 broadly includes a transferstructure 151 that defines a first aperture 154A. In operation, thefirst aperture 154A alternately accommodates: i) the first mold stack106A arranged therein, as shown in FIG. 2A, and more particularly, andwithout limiting the generality of the foregoing, the first stackportion 110 thereof; and ii) the first molded article 102A receivedtherein, as shown in FIG. 2B, with opening of the first mold stack 106A,along a mold-stroke axis X, to retract it from the first aperture 154A.As also shown in FIGS. 3 and 4, the transfer structure 151 furtherdefines a first branch channel 156A and a first trunk channel 158Athrough which the first molded article 102A is passable upon ejectionfrom the first stack portion 110. More particularly, the first branchchannel 156A connects the first aperture 154A with the first trunkchannel 158A for passing, in use, the first molded article 102A thereto,whereafter it passes through the first trunk channel 158A towards anexit 164A thereof. The first branch channel 156A and the first trunkchannel 158A being arranged to extend in different directions. Atechnical effect of the foregoing may include being able to pass thefirst molded article 102A through the injection mold along a pathwaythat avoids other structures of the mold, not the least of which mayinclude other mold stacks.

In the present non-limiting embodiment the transfer structure 151includes, as shown with reference to FIG. 2A, a transfer plate 152 thatis associated, in use, with the first mold half 96. The transfer plate152 defines, in part, the first aperture 154A, the first branch channel156A, and the first trunk channel 158A. The transfer structure 151 alsoincludes a cooperating structure 159 that is provided by a front face ofthe second mold shoe 131 with which to enclose the first branch channel156A and the first trunk channel 158A along at least a portion thereof.As such, the stripper retainer 153 is operable, during normal operation,to maintain the transfer plate 152 in contact with the cooperatingstructure 159 of the second mold shoe 131 throughout a period of timerequired to transfer the first molded article 102A through the moldedarticle transfer device 150. In practice, the foregoing may includebiasing the transfer plate 152 to remain in contact with the cooperatingstructure throughout relative movement between the first mold half 96and the second mold half 98 between the mold closed configuration C, asshown in FIG. 2A, and the mold open configuration O, as shown in FIG.2B. One exception to the foregoing is during the execution of a start-upmolding process. As the name implies, the start-up molding process wouldtypically be executed, although not exclusively, when starting theinjection mold 100. As generally known, the start-up of an injectionmold often requires manual intervention by a molding system operator toclear short-shots (i.e. molded articles that are only partially molded),to remove molded articles that stubbornly resist ejection (e.g.typically due to an over cooling thereof), or to remove flash (i.e.molding material that has seeped outside of the molding cavity 101), andthe like. Thus, during start-up it may be necessary to position thefirst mold half 96 and the second mold half 98, along the mold-strokeaxis X, such that a space is provided between the transfer plate 151 andthe cooperating structure 159 of the second mold shoe 131 to provideready access to each of the first stack portion 110 and the second stackportion 120.

Again with reference to FIGS. 3 and 4, it may be appreciated that thetransfer structure 151 further defines a first nozzle 162A that isarranged to dispense fluid, as shown in FIG. 3, in a direction thaturges the first molded article 102A that is received in the firstaperture 154A to pass through the first branch channel 156A towards thefirst trunk channel 158A. The first nozzle 162A may furthermore bearranged to dispense the fluid through the first aperture 154A above thefirst molded article 102A and towards the second stack portion 120 tourge the first molded article 102A away from the second stack portion120. A technical effect of the foregoing may include preventing thefirst molded article 102A from re-entering a cavity 124 that is definedin the cavity insert 122 of the second stack portion 120, upon ejectionfrom the first stack portion 110, whereby the first molded article 102Ais able to pass through the first branch channel 156A.

While the injection mold 100 thus far has been described as having afirst mold stack 106A, it may otherwise include an array of mold stacks.Such an array of mold stacks may include one or more columns of moldstacks.

As such, the transfer structure 151, including the transfer plate 152,of the molded article transfer device 150 may further define, as shownwith reference to FIG. 4, a first column of apertures 155A, includingthe first aperture 154A. The first column of apertures 155A alternatelyaccommodates: i) a first column of mold stacks 107A of the injectionmold 100 arranged therein, including the first mold stack 106A; and ii)a first column of molded articles 104A received therein, including thefirst molded article 102A, with opening of the first column of moldstacks 107A, along the mold-stroke axis X, to retract them from thefirst column of apertures 155A. Furthermore, the transfer structure 151may define a first column of branch channels 157A, including the firstbranch channel 156A. Each of the first column of branch channels 157Abeing arranged to connect one of the first column of apertures 155A withthe first trunk channel 158A for passing, in use, one of the firstcolumn of molded articles 107A thereto, whereafter they pass through thefirst trunk channel 158A towards the exit 164A thereof.

In a similar manner, and thus without further explanation, the transferstructure 151 may further define similar structure to transfer themolded articles produced by other columns of mold stacks. For sake ofillustration, these similar structures have been identified in FIG. 4 asincluding cooperating structures of a second column of apertures 155B, asecond column of branch channels 157B, and a second trunk channel 158Bwith which to transfer a second column of molded articles 104B from asecond column of mold stacks 107B. Likewise, a third column of apertures155C, a third column of branch channels 157C, and a third trunk channel158C are provided with which to transfer a third column of moldedarticles 104C from a third column of mold stacks 107C.

As illustrated, the first trunk channel 158A is arranged in between thefirst column of apertures 155A and the second column of apertures 155B,the second trunk channel 158B is arranged in between the second columnof apertures 155B and the third column of apertures 155C, and the thirdtrunk channel 158C is in turn arranged to the other side of the thirdcolumn of apertures 155C. Given the tight spacing between columns ofmold stacks in a typical injection mold, the first column of apertures155A and the first trunk channel 158A may be arranged to extend,although not exclusively, in parallel directions along a major portionthereof. Also, given the columnar arrangement of the mold stacks, eachof the first column of branch channels 157A are arranged to extend away(i.e. at an angle) from the first column of apertures 155A to intersectwith the first trunk channel 158A. Also, given that most injection moldsare mounted in a horizontal-type injection molding system 900 (i.e. themold-stroke axis X is horizontal), it is furthermore possible to arrangethe first trunk channel 158A and each of the first column of branchchannels 157A to extend in directions, wherein the first column ofmolded articles 104A are passable therethrough, in use, under influenceof gravity. The foregoing arrangements may also be applied with regardsto the remaining columns of apertures, branch channels and trunkchannels.

The transfer structure 151 may also define a first column of nozzles163A, included in which is the first nozzle 162A, each of which beingarranged to dispense fluid, in use, in a direction that urges the firstcolumn of molded articles 104A that are received in the first column ofapertures 155A to pass through the first column of branch channels 157Atowards the first trunk channel 158A. Furthermore, the first column ofnozzles 163A may be arranged to dispense fluid through the first columnof apertures 155A above the first column of molded articles 104A andtowards the second stack portion 120 of each of the first column of moldstacks 107A to urge the first column of molded articles 104A away fromthe second stack portion 120 of each of the first column of mold stacks107A.

In a similar manner, and thus without further explanation, the transferstructure 151 may further define further columns of nozzles inassociation with the other columns of apertures and the like.

With reference to FIG. 5, the molded article transfer device 150 mayfurther include a plurality of flow control devices 169 that arearranged between a fluid source 170 (e.g. air) and the first column ofnozzles 163A for controlling flow of the fluid thereto. Moreparticularly, of the four nozzles identified in the first column, namelythe first nozzle 162A, a second nozzle 162B, a third nozzle 162C, and afourth nozzle 162D, these are each separated from the fluid source via acorresponding one of a first valve 168A, a second valve 168B, a thirdvalve 168C, and a fourth valve 168D that are connected thereto via afirst line 160A, a second line 160B, a third line 160C, and a fourthline 160D. The valves may be controllable, such with a manuallyadjustable valve or an electrically operated spool valve, or mayotherwise be a fixed pressure drop device such as an orifice valve andthe like. As such, the plurality of flow control devices 169 may beconfigured to control the dispensing, in use, of fluid through the firstcolumn of nozzles 163A for sake of, for example, one or more of: i)dispensing of the fluid through at least the first nozzle 162A and thesecond nozzle 162B of the first column of nozzles 163A at different flowrates; ii) dispensing of the fluid through at least the first nozzle162A and the second nozzle 162B of the first column of nozzles 163A overdifferent intervals; iii) beginning dispensing of the fluid through atleast the first nozzle 162A and the second nozzle 162B of the firstcolumn of nozzles 163A at different points in time.

The focus of the description shall now shift to the construction andoperation of an alternative non-limiting embodiment of the injectionmold 100, as shown with reference to FIG. 6A, that further includes anin-mold shutter 140 such as that described in commonly assigned U.S.Patent Application 61/264,883 to Halter et al., filed on Nov. 30, 2009.With the inclusion of the in-mold shutter 140, it is possible to openand close the plurality of mold stacks, included in which is the firstmold stack 106A, without having to keep repositioning the moving platen912 relative to the stationary platen 914 to position the first moldhalf 96 and the second mold half 98 of the injection mold 100 betweenthe mold closed configuration C, as shown in FIG. 2A, and the mold openconfiguration O, as shown in FIG. 2B. A technical effect of theforegoing may include, amongst others, a shortening of the molding cycletime, wherein a component of time that was formerly contributed by thecertain operations of the clamping assembly 996 have been removed. Thatis, the production cycle no longer involves waiting for the clampshutter 920 to be successively (i.e. with each molding cycle)un-shuttered and re-shuttered, and nor does it require waiting for themovements, to and fro, of the moving platen 912.

The in-mold shutter 140 is associated with the first mold half 96. Moreparticularly, the in-mold shutter 140 is disposed between the movingplaten 912 and the first mold shoe 130 of the injection mold 100. Thein-mold shutter 140 broadly includes a shutter member 144 and a linkmember 146. As shown, the shutter member 144 is associated with themoving platen 912 of the clamping assembly 996, and the link member 146is associated with the first mold shoe 130. In operation, the shuttermember 144 is alternately selectively positioned, in use, in: i) a shutposition S (FIG. 6A) and ii) an open position U (FIG. 6B). As such, thein-mold shutter 140 further includes a shutter actuator 148 that isconnected to the shutter member 144, the shutter actuator 148 beingoperable, in use, to drive the movement of the shutter member 144between the open position U and the shut position S. With the shuttermember 144 arranged in the shut position S, as shown in FIG. 5A, theshutter member 144 is engaged with the link member 146, whereby thefirst mold shoe 130 is engaged with the moving platen 912. With theshutter member 144 arranged in the open position U, as shown in FIG. 6B,the shutter member 144 is disengaged from the link member 146, wherebythe first mold shoe 130 may be moved, in use, along the mold-stroke axisX. The movement of the first mold shoe 130, along the mold-stroke axisX, may be driven, for example, by the ejector actuator 922 of theclamping assembly 996. The foregoing is schematically shown withreference to FIG. 6A, wherein the ejector actuator 922 is shown to beconnected to the first core retainer 132.

The in-mold shutter 140 further includes a support base 142 upon whichthe shutter member 144 is slidably coupled, and wherein the support base142 is structured to be fixedly connected, in use, by a fastener 192, orthe like, to the moving platen 912. Furthermore, the link member 146 isconnected to a back face of the first core retainer 132 of the firstmold shoe 130. In this arrangement, the link member 146 is aligned withthe first stack portion 110 of the first mold stack 106A. Likewise,where the injection mold 100 includes a plurality of mold stacks,included in which is the first mold stack 106A, with which to define aplurality molding cavities to mold, in use, a plurality of moldedarticles, such as that shown with reference to FIGS. 2A and 2B, thein-mold shutter 140 may further include a plurality of link members,included in which is the link member 146, wherein each of the pluralityof link members is aligned with one of the plurality of mold stacks.That being said, no such specific limitation as to the number andarrangement of the link members is intended.

The shutter member 144 further defines a first clearance aperture 145that is configured to accommodate the link member 146 being arrangedtherein, in use, with the shutter member 144 being positioned in theopen position U (FIG. 6B) and with the movement of the first mold shoe130, along the mold-stroke axis X, towards a retracted position B (FIG.6E). Depending on the required stroke of the first mold shoe 130, thefirst clearance aperture 145 may be structured to extend, as shown,through the shutter member 144. Furthermore, the support base 142 mayalso define a second clearance aperture 143 that is aligned, in use,with the first clearance aperture 145, with positioning of the shuttermember 144 into the open position U. As such, the second clearanceaperture 143 is configured to accommodate the link member 146 beingarranged therein, in use, with the shutter member 144 being positionedin the open position U and with the movement of the first mold shoe 130,along the mold-stroke axis X, towards the retracted position B.

The shape and size of the link member 146 in relation to those of thefirst clearance aperture 145 and the second clearance aperture 143 isnot particularly limited so long as the link member 146 is arrangeabletherethrough. In the present non-limiting example, the link member 146has a cylindrical body, and wherein the first clearance aperture 145 andthe second clearance aperture 143 are provided as complementarycylindrical bores.

As previously mentioned, the transfer plate 152 is associated, as shownin FIG. 2A, with the first mold half 96 of the injection mold 100. Assuch, the in-mold shutter 140 is further provided with an ejector box147 with which to frame the first mold shoe 130 and otherwise couple, inuse, the transfer plate 152 of the molded article transfer device 150with the moving platen 912 of the injection molding system 900. Moreparticularly, a fastener 192 connects the transfer plate 152 to a top ofthe ejector box 147 and another fastener 192 connects the support base142 of the in-mold shutter 140 to a bottom of the ejector box 147,recalling that the support base 142 is fixedly connected, in use, by afastener 192, or the like, to the moving platen 912. Furthermore, theejector box 147 defines a space 149 within which the first core retainer132 and the second core retainer 133 may be moved, in use, along themold-stroke axis X. It is worth noting that in this non-limitingembodiment, the stripper retainer 136 is fastened to the transfer plate152. As previously mentioned, the movement of the first mold shoe 130,along the mold-stroke axis X, may be driven, at least in part, by theejector actuator 922 of the clamping assembly 996. More particularly,the ejector actuator 922 is shown to be connected to the first coreretainer 132 for a repositioning thereof. Furthermore, and as shown inFIG. 6A, the injection mold 100 further includes a stripper actuator 253that is connected to the stripper retainer 136 and the second coreretainer 133, the stripper actuator 253 being operable, in use, to movethe second core retainer 133 relative to the stripper retainer 136 alongthe mold-stroke axis X.

An injection molding process involving the injection mold 100 having anin-mold shutter 140 is illustrated in FIGS. 6A-6G. The molding processbegins, as shown in FIG. 2A, with the injection mold 100 beingpositioned in the mold closed configuration C with the first mold shoe130 being positioned, along the mold-stroke axis X, in an extendedposition E such that the first mold stack 106A is closed to define themolding cavity 101 therein. In so doing, the first mold stack 106A isarranged within the first aperture 154A that is defined by the transferplate 152 molded article transfer device 150. Furthermore, the shuttermember 144 of the in-mold shutter 140 is in the shut position S, wherebythe first mold shoe 130 is engaged with the moving platen 912.Accordingly, the injection mold 100 is configured for molding of thefirst molded article 102A. Thereafter, molding of the first moldedarticle 102A (not shown) is performed with injection of molding materialinto the molding cavity 101.

The injection molding process next includes, as shown with reference toFIG. 6B, the un-shuttering of the in-mold shutter 140 to disengaged thefirst mold shoe 130 from the moving platen 912. The un-shuttering of theshutter member 144 includes shifting the shutter member 144 into theopen position U, through control of the shutter actuator 148, whereinthe shutter member 144 is disengaged from the link member 146.

The injection molding process next includes, as shown with reference toFIG. 6C, opening of the first mold stack 106A with retracting the firststack portion 110, along the mold-stroke axis X, to position the firstmolded article 102A that is arranged thereon in the first aperture 154A.This involves retracting the first core retainer 132 and the second coreretainer 133, along the mold-stroke axis X, and thus the retracting ofthe inner core 112 that is retained thereto, wherein the outer core 114and the stripper sleeve 116 retract with the inner core 112 by virtuebeing linked together therewith by the first molded article 102A. Theretracting of the first core retainer 132 and the second core retainer133 is provided through control of the ejector actuator 922 and thestripper actuator 253, respectively.

The injection molding process next includes, as shown with reference toFIG. 6D, a first stage of arranging the first stack portion 110 to ejectthe first molded article 102A into the first aperture 154A, and moreparticularly the stripping of the seal portion 103 of the first moldedarticle 102A from where it was molded in between the inner core 112 andthe outer core 114 with relative movement thereof. As shown, with thecompletion of the last step the stripper sleeve 116 has reached itsrearward limit of travel within the pocket 138 and thus the first moldedarticle 102A is prevented from retracting any further with the innercore 112 or the outer core 114. As such, the present step involvesretracting the first core retainer 132, through control of the ejectoractuator 922, to retract the inner core 112 that is retained thereon,along the mold stroke axis X, a distance, relative to the outer core 114which is kept immobile by virtue of being arranged within the firstmolded article 102A, that is sufficient to strip the seal portion 103.

The injection molding process next includes, as shown with reference toFIG. 6E, a final stage of arranging the first stack portion 110 to ejectthe first molded article 102A into the first aperture 154A, andfurthermore opening of the first mold stack 106A with retracting of thefirst stack portion 110 from the first aperture 154A. The foregoinginvolves retracting the first core retainer 132, along the mold strokeaxis X, into the retracted position B, through control of the ejectoractuator 922, to retract the inner core 112 that is retained thereon adistance that is sufficient to further move the outer core 114 intostripping position by virtue of the inner core 112 having reached itsrearward limit of travel relative to the outer core 114 as defined bythe bayonet 113 in cooperation with the bayonet pocket 117. The firstmolded article 102A is stripped from the outer core 114 as it is held inthe first aperture 154A, through supporting contact with a top of thestripper sleeve 116, and the outer core 114 is retracted therefrom withits retraction to the stripping position.

The injection molding process next includes, as shown with reference toFIG. 6F, dispensing fluid through the first nozzle 162A to urge thefirst molded article 102A (not shown) to pass from the first aperture154A through the first branch channel 156A to the first trunk channel158A. Once received in the first trunk channel 158A, the first moldedarticle 102A passes therethrough to the exit 164A (FIG. 4) thereof underthe influence of gravity and/or with the assistance of air or some otherfluid being directed therethrough.

The injection molding process ends, as shown with reference to FIG. 6G,with closing of the first mold stack 106A. The closing of the first moldstack 106A involves rearranging the first mold shoe 130 into theextended position E with extension of the first core retainer 132 andthe second core retainer 133, along the mold stroke axis X, throughcontrol of the ejector actuator 922, and the stripper actuator 253,respectively, to extend the inner core 112 and the outer core 114 intotheir respective molding positions and in so doing push the strippersleeve 116 to its molding position with sliding movement thereof withinthe pocket 138. While not shown, prior to molding of the another of thefirst molded article 102A, there is a further requirement for shutteringof the in-mold shutter 140 to engage the first mold shoe 130 to themoving platen 912.

The focus of the description shall now shift to the construction andoperation of another alternative non-limiting embodiment of theinjection mold 200, as shown with reference to FIG. 7. The injectionmold 200 is structured similarly to the injection mold 100 of FIG. 2A,and as such only the differences of construction and operation thereofwill be described in detail in the description that follows.

One such difference is that the first mold half 196 and the second moldhalf 198 of the injection mold 200, and more particularly the first moldstack 206A, the first mold shoe 230, and the second mold shoe 231thereof, have been structured to accommodate a pair of movable splitmold inserts 218 with which to mold an encapsulated portion of the firstmolded article 102A (which in the present example is a tamper evidentband of a bottle closure).

More particularly, the first stack portion 210 includes an inner core212, an outer core 214, a stripper sleeve 216 and the pair of split moldinserts 218 that cooperate, in use, with a cavity insert 222 of thesecond stack portion 220 to define the molding cavity 101.

Likewise, the first mold shoe 230 is most notably different than thefirst mold shoe 130 described previously in that it now also includes asplit insert retainer 239 with which to retain and operate, in use, thepair of split mold inserts 218. The structure and operation of the splitinsert retainer 239 is well known in the art and thus will not bedescribed in detail herein. Suffice it to state that the first retainerincludes, as shown, a split retainer plate 237 to which a pair ofconnecting bars 235 are slidably mounted. The pair of split mold inserts218, namely a first split half 218A and a second split half 218B, aremounted to the pair of connecting bars 235, and thus are retained formovement with the split insert retainer 239. In operation, the pair ofconnecting bars 235 are movable along an axis that is generallyperpendicular to the mold-stroke axis X, whereby the first split half218A and the second split half 218B are moved between a closed and anopen configuration to form an encapsulated portion of the molding cavity101 and otherwise release the encapsulated portion of the first moldedarticle 102A, respectively.

The molded article transfer device 250 is different than the moldedarticle transfer device 150 described previously in that the transferplate 252 defines a pocket 238 beneath the first aperture 254A withinwhich to slidably retain the stripper sleeve 216 to accommodate, in use,movement thereof along the mold-stroke axis X. Another difference isthat the molded article transfer device 250 is arranged between thesplit insert retainer 239 and the other members (not shown) of the firstmold half 230. In this way, the transfer structure 251 that defines afirst branch channel 256A and a first trunk channel 258A also includesthe cooperating structure 259 that is provided on a rear face of a splitinsert retainer 239. That is, the cooperating structure 259 encloses thefirst branch channel 256A and the first trunk channel 258A of the moldedarticle transfer device 250.

The focus of the description shall now shift to the description of aninjection molding process 300, as shown in FIG. 8, that is executable ona controller 501, as shown with reference to FIG. 1, such as the onethat is typically associated with the injection molding system 900. Thecontroller 501 is shown to be connected to the platen-moving actuator915 and the ejector actuator 922 of the injection molding system 900 forthe control thereof. Likewise, some or all of the stripper actuator 153,253, the shutter actuator 148, and the plurality of flow control devices169 may be similarly connected thereto.

Accordingly, the controller 501 may include instructions 512 that areembodied in a controller-usable memory 510 of the controller 501, theinstructions 512 for directing the controller 501 to execute the moldingprocess 300, as shown in FIG. 8, that includes the steps of:

(i) closing 302 the first column of mold stacks 107A of the injectionmold 100, 200, wherein the first column of mold stacks 107A are arrangedwithin the first column of apertures 155A;

(ii) molding 304 a first column of molded articles 104A within the firstcolumn of mold stacks 107A;

(iii) opening 306 the first column of mold stacks 107A to retract themfrom the first column of apertures 155A;

(iv) arranging 308 the first column of mold stacks 107A to eject thefirst column of molded articles 104A into the first column of apertures155A; and

(v) dispensing 310 fluid through the first column of nozzles 163A tourge the first column of molded articles 104A that are received in thefirst column of apertures 155A to pass through a first column of branchchannels 157A towards the first trunk channel 158A that are defined bythe transfer structure 151.

Furthermore, the step of dispensing 310 may further include controllingthe plurality of flow control devices 169 for controlling flow of thefluid through the first column of nozzles 163A for sake of one or moreof: dispensing 310 of the fluid through at least the first nozzle 162Aand the second nozzle 162B of the first column of nozzles 163A atdifferent flow rates; dispensing 310 the fluid through at least thefirst nozzle 162A and the second nozzle 162B of the first column ofnozzles 163A over different intervals; and/or beginning the dispensing310 of the fluid through at least the first nozzle 162A and the secondnozzle 162B of the first column of nozzles 163A at different points intime.

It is also worth noting that the sequence in which the molding process300 is to be executed is not particularly limited. For example, thesteps of opening 306 and the arranging 308 of the first column of moldstacks 107A may be performed sequentially or concurrently, at least inpart.

It is noted that the foregoing has outlined some of the more pertinentnon-limiting embodiments. These non-limiting embodiments may be used formany applications. Thus, although the description is made for particulararrangements and methods, the intent and concept of these non-limitingembodiments may be suitable and applicable to other arrangements andapplications. It will be clear to those skilled in the art thatmodifications to the disclosed non-limiting embodiments can be effected.The described non-limiting embodiments ought to be construed to bemerely illustrative of some of the more prominent features andapplications thereof. Other beneficial results can be realized byapplying these non-limiting embodiments in a different manner ormodifying them in ways known to those familiar with the art. Thisincludes the mixing and matching of features, elements and/or functionsbetween various non-limiting embodiments is expressly contemplatedherein, unless described otherwise, above.

What is claimed is:
 1. An injection mold (200), comprising: a first moldstack (206A) that is configured to define a molding cavity (101) withinwhich a first molded article (102A) is moldable; a first mold half (196)that includes a first stack portion (210) of the first mold stack (206A)associated therewith; a second mold half (198) that includes a secondstack portion (220) of the first mold stack (206A) associated therewith;the first mold half (196) being configured to cooperate with an in-moldshutter (140) to permit opening and closing of the mold stack (206A)substantially without repositioning of the first mold half (196)relative to the second mold half (198); wherein the first mold stack(206A) includes a pair of movable split mold inserts (218) with which tomold an encapsulated portion of the first molded article (102A).
 2. Theinjection mold (200) of claim 1, wherein: the first mold stack (206A) isconfigured to mold a bottle closure, and the split mold inserts (218)are configured to mold a tamper evident band thereof.
 3. The injectionmold (200) of claim 1, wherein: the first mold half (196) includes afirst mold shoe (230) with the first stack portion (210) of a first moldstack (206A) connected thereto; the second mold half (198) includes asecond mold shoe (231) with the second stack portion (220) of the firstmold stack (206A) connected thereto.
 4. The injection mold (200) ofclaim 3, wherein: the first mold shoe (230) includes a split insertretainer (239) with which to retain and operate, in use, the pair ofsplit mold inserts (218).
 5. The injection mold (200) of claim 4,wherein: the in-mold shutter (140) is configured to cooperate with thefirst mold shoe (130).
 6. The injection mold (200) of claim 5, wherein:the in-mold shutter (140) includes a shutter member (144) and a linkmember (146), wherein the shutter member 144 is associated with a movingplaten (912) of a clamping assembly (996), and the link member (146) isassociated with the first mold shoe (130), wherein the shutter member(144) is selectively positionable between a shut position (S) and anopen position (U), whereby the first mold shoe (130) may be selectivelyengaged with the moving platen (912).
 7. The injection mold (200) ofclaim 4 wherein: the first mold half (196) further includes a moldedarticle transfer device (250) that is configured to transfer the firstmolded article (102A) that is received from a first mold stack (206A).8. The injection mold (200) of claim 7, wherein: the molded articletransfer device (250) includes a transfer structure (251) that defines:a first aperture (154A) that is structured to receive the first moldedarticle (102A) from the first mold stack (206A); a first branch channel(156A) and a first trunk channel (158A) through which the first moldedarticle (102A) is passable, wherein the first branch channel (156A)connects the first aperture (154A) with the first trunk channel (158A)for passing, in use, the first molded article (102A) thereto, whereafterit passes through the first trunk channel (158A) towards an exit (164A)thereof.
 9. The injection mold (200) of claim 5 wherein: the first moldhalf (196) further includes a molded article transfer device (250) thatis configured to transfer the first molded article (102A) that isreceived from a first mold stack (206A).
 10. The injection mold (200) ofclaim 9, wherein: the molded article transfer device (250) includes atransfer structure (251) that defines: a first aperture (154A) that isstructured to receive the first molded article (102A) from the firstmold stack (206A); a first branch channel (156A) and a first trunkchannel (158A) through which the first molded article (102A) ispassable, wherein the first branch channel (156A) connects the firstaperture (154A) with the first trunk channel (158A) for passing, in use,the first molded article (102A) thereto, whereafter it passes throughthe first trunk channel (158A) towards an exit (164A) thereof.
 11. Theinjection mold (200) of claim 6 wherein: the first mold half (196)further includes a molded article transfer device (250) that isconfigured to transfer the first molded article (102A) that is receivedfrom a first mold stack (206A).
 12. The injection mold (200) of claim11, wherein: the molded article transfer device (250) includes atransfer structure (251) that defines: a first aperture (154A) that isstructured to receive the first molded article (102A) from the firstmold stack (206A); a first branch channel (156A) and a first trunkchannel (158A) through which the first molded article (102A) ispassable, wherein the first branch channel (156A) connects the firstaperture (154A) with the first trunk channel (158A) for passing, in use,the first molded article (102A) thereto, whereafter it passes throughthe first trunk channel (158A) towards an exit (164A) thereof.